Aircraft Assembly Positioner Simulation Using Equivalent Spring Models
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Solution Overview
Problem
Existing numerical simulations for aircraft assembly positioners are time-consuming and sensitive to imperfections in the assembly line floor, requiring complex calculations and compromising accuracy.
Innovation Solution
A simplified simulation method using equivalent springs to model positioners, combined with a stiffness adapter to compensate for imperfections, allowing quick and accurate positioning of positioners relative to fuselage and wing loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If numerical simulations are performed using finite element models of the positioners, then the accuracy of modeling the interactions between the fuselage and wing and the positioners is improved, but the simulation time increases significantly
Solution Approach 1:
The patent changes the modeling parameters from detailed finite element models to simplified equivalent spring models with stiffness coefficients. This parameter transformation maintains the essential mechanical behavior while dramatically reducing computational complexity and simulation time, directly resolving the contradiction between modeling accuracy and simulation time
Solution Approach 2:
The patent creates simplified copies of the positioner structures using equivalent spring elements that replicate the essential load-bearing characteristics without the computational burden of full finite element models. These simplified models capture the key interaction behaviors while enabling rapid simulation cycles
2Measurement precision
If numerical simulations are performed using finite element models, then detailed interaction analysis is improved, but the complexity of calculations and analyses increases
Solution Approach 1:
The patent extracts only the essential mechanical characteristics of the positioners (stiffness properties) and represents them with simplified spring elements. This extraction removes unnecessary computational complexity while retaining the critical interaction analysis capabilities needed for positioner evaluation
Solution Approach 2:
The patent transforms complex finite element model parameters into simplified equivalent stiffness coefficients. This parameter reduction maintains the ability to analyze positioner-fuselage-wing interactions while dramatically reducing calculation complexity and making the simulations more tractable
3Measurement precision
If high accuracy simulations are performed, then positioning precision is improved, but the simulations become sensitive to imperfections in the assembly line floor
Solution Approach 1:
The patent converts the harmful sensitivity to floor imperfections into a benefit by using the simplified spring models that can more easily incorporate floor irregularities as additional spring elements or boundary conditions. This approach allows the model to adapt to real-world conditions rather than being disrupted by them
Solution Approach 2:
The patent changes from rigid, high-precision finite element models to flexible equivalent spring models that can accommodate floor imperfections through adjusted stiffness parameters. This parameter flexibility reduces sensitivity to assembly line floor variations while maintaining positioning precision
Data Source
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Figure 3~4A
AI summary
A simulation of the forces applied to positioners designed to support the fuselage and wings of an aircraft during assembly operations is performed. The forces are defined in a numerical model of the aircraft's load plane during assembly. The simulation is carried out using the numerical model of the aircraft's load plane during assembly and a numerical model of each positioner as a set of three equivalent springs defined by three respective eigenvectors associated with three respective eigenvalues, where the eigenvalues provide stiffness values and the eigenvectors provide directions along which the respective eigenvalues are applied. This reduces simulation time.